Powder feeder, powder filling and packaging machine, and method of manufacturing powder package

ABSTRACT

[Object] To provide a powder supply device, a powder filling packaging machine and a method of manufacturing a powder package capable of high-speed operation while suppressing false operations. 
     [Means to Attain the Object] A powder supply device includes: a member  1  including a plate portion having holes  2  formed to penetrate through the plate portion; a moving mechanism  18  that moves the member  1  in such a manner that top openings of the holes  2  move along a specific moving path; an opening/closing member  5  that makes bottom openings of the holes  2  in closed state and opened state as the member  1  moves; a powder filling unit  14  that fills a specific amount of powders  3  in each of the holes  2  within a predetermined section in the moving path; and a sensor  4  that is provided above a path within a section other than the predetermined section in the moving path and that continuously monitors the moving path on the plate portion.

TECHNICAL FIELD

The invention relates to a powder supply device for monitoring dropping failures, which means that a predetermined amount of powders are not dropped from a measuring box when various types of powders are supplied using measuring boxes, with less-frequent detection errors, to a powder filling packaging machine for filling the powders in a packaging bag and sealing the packaging bag, and to a method of manufacturing a powder package.

Various medicines, agrichemicals, condiments such as granulated sugar, deoxidant containing iron powder or oxidizable compound as main material, or other powders are well known as a product form of a small paper or plastic bag packaging a specific amount of the powders. When powders are packaged, a powder filling packaging machine is typically used for automation. The powder filling packaging machine measures a specific amount of powders and then guide the specific amount of powders into a packaging bag through a chute or the like. In order to measure powders, a measuring method in volume in which powders are filled in a space of a specific volume (measuring box) is often used.

During operation of the powder filling packaging machine, there may occur an operation failure of a shutter mechanism for a bottom opening of the measuring box, a failure of filling a specific amount in the measuring box due to filling hindering by a foreign substance or the like in a filling unit, or a trouble (filling failure) such that an amount of powders in the measuring box right before dropping the powders is below a specific amount due to leaking through the bottom opening after filling. Further, there may occur a trouble (dropping failure) such that powders are dropped after the measuring box has passed a position where the powders are supposed to be dropped from the measuring box, or whole or some of powders are not dropped due to clogging with powders in the measuring box, a flow failure of the powders, an operation failure of the shutter mechanism for the bottom opening of the measuring box, or the like.

If such troubles occur, a packaging bag is not filled with a specific amount of powders and thus becomes a nonconforming product. As a method of detecting such nonconforming product, weight detection in which weight of each powder package is measured one by one is generally known. However, the method cannot be adapted for a high-speed automated filling packaging. In addition, the method cannot be adapted for connected package form in which powder packages are not separated into individual packages but connected in a band shape. Therefore, a method of sampling a powder package out of sequentially produced powder packages once in every specific time or for a specific number of powder packages to measure weight thereof has been typically used.

Once a failure due to clogging with powders in the measuring box or clogging with a foreign substance occurs, such failure condition often continues. In the case, the sampling method is effective.

However, when a failure condition occurs suddenly, the failure condition cannot be found by the sampling method. Therefore, a method in which a phototube is arranged at a specific position of the powder filling packaging machine where powder packages pass to detect height of filled powders for all filled powder packages based on transmitted light amount, and a method in which two small rollers sandwich the powder packages to detect that a thickness of each of the powder packages is a specific value or more are known.

However, these methods have large margin of errors due to variations in individual powder packages caused when the packages are produced and due to shape difference of filled powders caused by vibration. On the other hand, if these methods are used with higher sensitivity, false operations increase. Further, when two kinds of powders of different volume ratios are filled in a powder package such as for some kind of deoxidant, shortage of one kind of powders of smaller volume ratio cannot be detected substantially, which is one of disadvantages of the methods. Accordingly, it has been significantly difficult to find if a correct amount of powders are filled in all powder packages.

Therefore, a device that checks if powders are securely filled in packages by detecting whether powders to be supplied to a package remain in a measuring box rather than directly checking presence/absence of powders filled in a package is proposed. Specifically, a depth measuring sensor for measuring a depth of the measuring box is arranged above a material measuring board corresponding to the measuring box when a shutter of a bottom opening of the measuring box is closed after the shutter of the bottom opening of the measuring box is opened to drop powders filled in the measuring box. Also, the device is configured to measure the depth of the measuring box with the depth measuring sensor when the shutter of the bottom opening of the measuring box is closed and compare the measured depth with a depth of the measuring box being empty, which is previously measured, thereby checking presence/absence of powders in the measuring box (Patent Document 1).

Patent Document 1: Japanese Patent No. 3662276 DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention

The checking device of powder supply disclosed in Patent Document 1 is required to recognize that the measuring box is moved to a position for irradiating laser light and then irradiate laser light at the timing. Also, the checking device of powder supply needs to calculate the depth of the measuring box based on reflected laser light. Further, the checking device of powder supply needs to compare the calculated depth with a normal depth, which is previously measured. As such described, a considerable burden is on the control of the device, and thus anomaly detection is time consuming, which is a disincentive for providing a high-speed device. In addition, if there occurs an asynchrony of movement timing of a plate on which the measuring boxes are arranged, or a rotation failure or a speed change of a rotating plate, it is difficult to determine whether laser light is irradiated to the measuring box or to top surface of the rotating plate, which increases false operation of the device.

The invention is accomplished in view of the above situation and an object thereof is to provide a powder supply device, a powder filling packaging machine and a method of manufacturing a powder package capable of high-speed operation due to simplified anomaly detection while suppressing false operation.

Means for Solving the Problems

As a result of a minute study of trouble events including filling failures of powders into a measuring box and dropping failures of powders from the measuring box, the inventors have found that it is sufficient to pay attention only to a position of an upper surface of powders in the measuring box with respect to both of the filling failures and the dropping failures. The inventors have found that particularly when a dropping failure, in which only some of powders in the measuring box are dropped, occurs, powders in upper portion of the measuring box remains in place while some of powders in lower portion of the measuring box are dropped in many cases. Also, the inventers have accomplished the device according to the invention with a confirmation through actual operation that false operation occurs much less often in the device and thus the device is highly effective and practical. Note that a hole that functions as a measuring box may be referred to as a measuring box hereinafter.

A powder supply device according to the invention includes: a member including a plate portion having holes formed to penetrate through the plate portion; a moving mechanism that moves the member in such a manner that top openings of the holes move along a specific moving path; an opening/closing member that makes bottom openings of the holes in closed state and opened state as the member moves; a powder filling unit that fills a specific amount of powders in each of the holes within a predetermined section in the moving path; and a sensor that is provided above a path within a section other than the predetermined section in the moving path and that continuously monitors the moving path on the plate portion.

A powder filling packaging machine according to the invention includes: a member including a plate portion having holes formed to penetrate through the plate portion; a moving mechanism that moves the member in such a manner that top openings of the holes move along a specific moving path; an opening/closing member that makes bottom openings of the holes in closed state and opened state as the member moves; a powder filling unit that fills a specific amount of powders in each of the holes within a predetermined section in the moving path; a guide unit that guides the powders dropped from the holes when the bottom openings of the holes are in opened state into a packaging bag; a sealing unit that seals the packaging bag in which powders guided by the guide unit are filled; and a sensor that is provided above the moving path within a section other than the predetermined section in the moving path and that continuously monitors the moving path on the plate portion.

A method of manufacturing a powder package according to the invention includes: moving a member including a plate portion having holes formed to penetrate through the plate portion in such a manner that top openings of the holes move along a specific moving path; making bottom openings of the holes in closed state by an opening/closing member; filling a specific amount of powders in each of the holes within a predetermined section in the moving path; making the bottom openings of the holes in opened state and dropping the powders in the holes; guiding the powders into a packaging bag positioned below the plate portion to fill the packaging bag; and sealing the packaging bag, wherein a sensor that is provided above a path within a section other than the predetermined section in the moving path continuously monitors the moving path on the plate portion and if anomaly is detected, a predetermined operation is performed.

In the powder supply device, the powder filling packaging machine, and the method of manufacturing a powder package of such configuration, the moving path of the top openings of the holes on the plate portion is continuously monitored, and thus upper surfaces of the powders in the holes and the main surface of the plate portion are continuously monitored. Accordingly, a control for operating the sensor at timing when any of the holes moves to a position where the sensor is provided or a control for the device to recognize that the device is monitoring any of the holes is not required. Therefore, a burden on the control of the device is very small, so that a high-speed device can be provided.

In addition, if the member including the plate portion is a disk, for example, false operations of the device can be suppressed even when there occurs asynchrony of movement timing of the disk on which the holes are arranged, or rotation failure or speed change of the disk.

Then, inferior items that are generated unexpectedly and that has been difficult to monitor can be precisely eliminated. Therefore, good items can be produced precisely, and then high quality powder packages can be provided to the market.

Further, the powder filling unit may be configured to deposit a specific amount of powders on the main surface of the plate portion. With such configuration, the states of the upper surface of the powders deposited on the main surface and the upper surface of the powders filled in the holes are monitored by monitoring the moving path of the top openings of the holes in the plate portion according to the invention.

Still further, it is preferable that the powders filled in the holes have the same height with the powders deposited on the main surface of the plate portion. With such configuration, if any change occurs in the sensor after the powders are filled and before the powders are dropped from the holes, a filling failure to the holes can be assumed. In addition, if any change does not occur in the sensor after the powders are dropped, a dropping failure can be assumed.

As described above, a failure can be detected without identifying positions of the holes, with simple and clear monitoring, and with minimum arithmetic processing causing processing time delay or burden on a control (sequencer). Therefore, machine stop and the like may be fed back at the same time the failure is monitored.

In addition, when a plurality of sensors are provided so as to monitor both of dropping failures and filling failures, highly precise filling packages can be managed highly precisely.

Further, in the invention, it is preferable that the sensor is provided above the moving path at a position of a hole after a specific amount of the powders are filled in the hole and before the opening/closing member makes the bottom opening of the hole in opened state. In addition, it is preferable that the monitoring is performed after a specific amount of the powders are filled in the hole and before the opening/closing member makes the bottom opening of the hole in opened state. With such configuration, powder filling can be monitored.

Further, in the invention, it is preferable that the sensor is provided above the moving path at a position where the bottom openings of the holes are in opened state. In addition, it is preferable that the monitoring is performed when the bottom openings of the holes are in opened state so that the powders being dropped from the holes are monitored. With such configuration, in the invention, output from the sensor when the sensor monitors the upper surface of the powders in a hole and that when the sensor monitors the main surface of the plate portion are significantly different if the powders are normally dropped from the hole. On the other hand, output from the sensor when the sensor monitors the upper surface of the powders in a hole and that when the sensor monitors the main surface of the plate portion are not different if the powders are not normally dropped from the hole. Therefore, dropping failures of the powders can be monitored precisely.

In the invention, it is preferable that the sensor is an optical sensor including: a light projecting unit that projects a light; and a light receiving unit that receives reflected light of the projected light, so as to detect an amount of the received light. With such configuration, advantages such as the monitoring is less affected by temperature change, less affected by difference of powder types, and highly precise.

Especially when the optical sensor is provided above the moving path at a position where the bottom openings of the holes are in opened state, the light projected into any of the holes from the light projecting unit passes through the hole if the powders are normally dropped from the holes. Therefore, the amount of received light of the light projected into any of the holes are significantly reduced comparing to the amount of received light in monitoring the state of the main surface of the plate portion and stable. Also if the powders are not dropped from the hole, so that a dropping failure occurs, a specific amount of light is reflected to the light receiving unit of the optical sensor. Dropping failures of the powders can be monitored with less frequent detection errors.

In addition, in the invention, it if preferable that the plate portion is in a disk shape, and the moving mechanism is a rotating mechanism that moves the member in such a manner that the plate portion rotates. With such configuration, holes can be arranged on a circumference and an operation to fill powders in the holes and the drop powders from the holes is repeated (circulated) as a circumferential angle is increased. Therefore, such configuration is suitable for a single-line packaging machine.

In the invention, it is also preferable that the moving mechanism is a reciprocating moving mechanism that reciprocates the member. With such configuration, powders are filled in the holes at an end of one reciprocating movement (start point of the forward path or end point of the backward path) and the powders are dropped from the holes at the other end of one reciprocating movement (end point of the forward path or start point of the backward path). Since all holes operate similarly in a reciprocating machine, the reciprocating machine is suitable for a multiple-line filling packaging machine.

Effect of the Invention

With the powder supply device, the powder filling packaging machine and the method of manufacturing a powder package according to the invention, high-speed operation is possible while suppressing false operation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view showing a light projecting state and a light receiving state of an optical sensor in a powder supply device and a powder filling packaging machine of the invention.

FIG. 2 is a view showing a powder supply device and a powder filling packaging machine of a first embodiment of the invention.

FIG. 3 is a view showing a powder supply device and a powder filling packaging machine of a second embodiment of the invention.

DESCRIPTION OF REFERENCE NUMERALS

-   1: member -   2: hole -   3: powder -   4: optical sensor -   5: opening/closing member -   7: scraping plate -   8: packaging bag -   13: hopper -   15: chute -   16: sealing unit -   18: moving mechanism -   2A: opening position of opening/closing member for bottom opening     measuring box -   2B: closing position of opening/closing member for bottom opening     measuring box -   2C: powder supply start position

DESCRIPTION OF EMBODIMENTS

Powders referred to in the invention are not limited to powdery materials each having a particle diameter of about 100 μm or smaller but include particulate or granular materials each having a particle diameter of millimeters or smaller, and thus include various medicines, agrichemicals, condiments such as granulated sugar, deoxidant containing iron powder or oxidizable compound as main material, and other materials.

Typical powder supply device and powder filling packaging machine according to the invention is provided with a member having plate portion that has a predetermined thickness and rotates or reciprocates along a main surface. In the plate portion, a plurality of holes penetrating through the plate portion is formed on a circumference or a straight line to function as measuring boxes. Further, opening/closing members are provided at bottom openings of the holes. At a position where the bottom openings of the holes are in closed state so as to function as measuring boxes, a specific amount of powders are filled in each hole. Then, at a position where the bottom openings of the holes are in opened state, the filled powders are dropped by gravity from the holes. The dropped powders are guided into small packages provided in a lower part through a chute that is a guide unit for filling. The invention may apply to such a powder supply device and a powder filling packaging machine that use a measuring method in volume (measuring box).

First Embodiment

First, a powder supply device and a powder filling packaging machine according to a first embodiment of the invention will be described referring to the accompanying drawings.

FIG. 1 shows a schematic cross sectional view illustrating a light projecting state and a light receiving state (shown by arrows) of an optical sensor corresponding to states while powders are filled in and dropped from holes in a plate portion of a member. FIG. 2 is a schematic view illustrating an operation of the powder supply device and the powder filling packaging machine using a rotating member. FIG. 2A is a plan view and FIG. 2B is a cross sectional view taken on line II-II in FIG. 2A.

The powder supply device includes: a member 1 having holes 2; moving mechanism 18 for moving the member 1 in a plane; opening/closing members 5; a powder filling unit 14; and an optical sensor 4 as shown in FIG. 2. The powder filling packaging machine includes: a chute 15 that is a guide unit for guiding powders 3 into packaging bags 8; and a sealing unit 16 for sealing the packaging bags 8 in addition to the powder supply device.

The member 1 is in a disk shape having a main surface. The member 1 as a whole is a plate portion. In this embodiment, the member 1 is in a plate shape, and thus the member 1 is called a plate member 1. On the plate member 1, twenty-four holes 2 penetrating the plate member 1 perpendicularly to the main surface are formed equiangularly along neighborhood of its circumference. The plate member 1 is configured to move in a predetermined rotating direction of the main surface direction. Accordingly, a moving path of top openings of the holes 2 forms a circle. And the holes 2 function as measuring boxes when bottom openings of the holes 2 are closed.

A hopper 13 is provided above the plate member 1. A scraping plate 7 is provided at the neighborhood of the circumference of plate member 1 at a predetermined distance from the main surface, which is an upper surface of the plate member 1, in such a manner that the scraping plate 7 can pass by the top openings of the holes 2. The hopper 13 and the scraping plate 7 make up the powder filling unit 14 that occupy a predetermined section of the moving path of the top openings of the holes 2 in a section where the bottom openings of the holes 2 are in closed state so as to fill specific amount of powders 3 in the holes 2.

The opening/closing members 5 are provided on the lower side of the plate member 1 at the same positions where the bottom openings of the holes 2 are provided. The opening/closing members 5 are configured to slide along the lower surface of the plate member 1 as the plate member 1 rotates so that the bottom openings of the holes 2 are in closed state/opened state. The upper surfaces of the opening/closing members 5 are subjected to a process for preventing the powders 3 from attaching thereto when the powders 3 are dropped.

The optical sensor 4 is provided above the plate member 1 at a position in the moving path of the top opening of the holes 2 where the opening/closing members 5 makes the bottom openings of the holes 2 in opened state. The optical sensor 4 includes a light projecting unit 41 for projecting light and a light receiving unit 42 for receiving reflected light.

The chute 15 is provided below the plate member 1 at a position where the opening/closing members 5 make the bottom openings of the holes 2 in opened state. The chute 15 functions as a guide unit for guiding the powders 3 dropped from the holes 2 into the packaging bags 8. The chute 15 is in a funnel shape having a larger opening on the plate member 1 side and a smaller opening on the packaging bag 8 side.

The sealing unit 16 for sealing the packaging bags 8 is provided at a place away from the plate member 1. The sealing unit 16 seals each of the packaging bags 8 by heat-sealing a part of the packaging bag 8.

Next, operation of the powder supply device and the powder filling packaging machine, and a method of manufacturing powder packages will be described.

As described above, the top openings of the holes 2 moves along a circular moving path as the plate member 1 rotates due to the moving mechanism 18. First, when one of the holes 2 is at a position 2C, the bottom opening of the hole 2 is made in closed state by its opening/closing member so that the hole 2 functions as a measuring box. Then, the powders 3 are supplied onto the plate member 1 through the hopper 13 having a measure.

After that, the hole 2 moves an angle for seven holes) (105°), the powders 3 are filled in the hole 2, and the powders 3 are measured by using the scraping plate 7. The scraping plate 7 fills a specific amount of the powders 3 in the hole 2 and also deposits the powders 3 on the main surface of the plate member 1 to a specific height.

When the plate member 1 rotates to move the hole 2 an angle for two holes)(30°) after the measurement, in other words, when the hole 2 is at a position 2A, the opening/closing member 5 makes the bottom opening of the hole 2 in opened state. Accordingly, the powders 3 in the hole 2 are dropped. The powders 3 dropped from the hole 2 are guided into the packaging bag 8 by the chute 15.

Next, when the plate member 1 rotates to move the hole 2 an angle for one hole (15°), the optical sensor 4 monitors to check if the powders 3 are dropped or the powders 3 are not dropped thereby causing a trouble. Specifically, the optical sensor 4 continuously monitors the moving path along which the top opening of the hole 2 in the plate member 1 moves and continuously monitors upper surfaces of the powders in the holes 2 and the upper surface of the powders on the main surface of the plate member 1. The monitoring will be described in detail later.

If the optical sensor 4 outputs anomaly, and thus a dropping failure of the powders is detected, an alarm in a form of sound or light is issued through an amplifier, a sequencer, a micro computer, or the like. Alternatively, various mechanical controls such as automatic ejection of a product effected by the dropping failure, partial stop or complete stop of the filling packaging machine, various operations of peripheral machines may be performed.

The hole 2 moves an angle for two holes (30°) after the optical sensor 4 monitors that the powders 3 are dropped, that is, the hole 2 moves for three holes (45°) from the position 2A. Then at a position 2B, the opening/closing member 5 makes the bottom opening of the hole 2 in closed state.

After that, the hole 2 moves an angle for twelve holes (180°) at the state to circulate back to the position 2C.

The operation that the powders 3 are dropped from the hole 2 into the packaging bag 8 will be now described.

The packaging bags 8, each having an opening only at its upper end, are continuously formed below the plate member 1 and moves together with the movement of the plate member 1. Specifically, the packaging bags 8 are controlled in such a manner that the opening of one of the packaging bags 8 is positioned right below the hole 2 before its opening/closing member 5 makes the bottom opening of the hole 2 in opened state, that is, before the hole 2 reaches the position 2A, and then the packaging bag 8 moves together with the movement of the hole 2.

At the position 2A, right before the opening/closing member 5 makes the bottom opening of the hole 2 in opened state, the lower opening of the chute 15 is inserted in the packaging bag 8. After that, the opening/closing member 5 makes the bottom opening of the hole 2 in opened state so as to drop the powders 3 into the chute 15. Accordingly, the powders 3 guided by the chute 15 are filled in the packaging bag 8.

Next, the operation that the packaging bag 8 is sealed, so that a powder package is completed will be described. The packaging bag 8 that has moved together with the hole 2 moving as the plate member 1 as described above moves from below of the plate member 1 to outside of the plate member 1 after the packaging bag 8 is filled with the powders 3 and before the holes 2 moves to the position 2C.

After that, the packaging bag 8 moves into the sealing unit 16. Then, the sealing unit 16 pinches the packaging bag 8 so that the upper opening of the packaging bag 8 is closed and then heats the upper end thereof. Accordingly, the opening of the packaging bag 8 is closed by heat-sealing, so that the packaging bag 8 is sealed. Consequently, a powder package is completed.

Here, the powder packages may be separated into individual packages afterward, or may be in a state of connected packages of a specific number of packages or other states.

In the above embodiment, the optical sensor 4 is provided at a position between a position where the powders 3 are dropped from the hole 2 and a position where the bottom opening of the hole 2 is made in closed state for a purpose of monitoring dropping failures of the powders 3. However, the optical sensor 4 may be provided at any position corresponding to a purpose as long as the sensor can monitor the upper side of the holes 2. The following positions can be given as preferable examples.

1) A position between a position where the bottom opening of the hole 2 is made in closed state, the powders 3 are filled in the holes 2, and the hole 2 passes by the scraping plate 7, so that a specific amount the powders 3 are measured and a position where the bottom opening of the hole 2 is made in opened state to start dropping the powders 3.

2) A position of the hole 2 right after the bottom opening of the hole 2 is made in opened state to start dropping the powders 3.

3) A position between a position where dropping of the powders 3 from the holes 2 is completed and a position where the bottom opening of the hole 2 is made in closed state.

4) A position between a position where the bottom opening of the hole 2 is made in closed state and a position where the powders 3 are filled in the hole 2 that functions as a measuring box again.

As such described, the optical sensor 4 can be provided above a specific path along which the top opening of the hole 2 moves at any position other than a predetermined section between a position where the powders are filled by the hopper 13 and a position where a specific amount of powders 3 are measured by the scraping plate 7.

Next, the operation that the optical sensor 4 monitors dropping of the powders or the like will be described.

FIG. 1A is a view illustrating the way of monitoring the state of the main surface of the plate member 1. In other words, FIG. 1A shows a state where the light projecting unit 41 projects light onto the upper surface of the powders deposited to a specific height on the main surface of the plate member 1, which is a portion where the holes 2 are not formed, and reflected light is received by the light receiving unit 42. The light receiving unit 42 can receive a specific amount of light out of the light that has been projected from the projecting unit 41 to the powders 3 on the main surface of the plate member 1 in stable condition.

FIG. 1B shows a state where the powders 3 are dropped normally from the hole 2 and thus the light that has projected from the projecting unit 41 passes through the hole 2. In this state, the amount of received light received by the light receiving unit 42 out of the light that has been projected from the light projecting unit 41 is significantly lower than that in the state shown in FIG. 1A.

FIG. 10 shows a state where the powders 3 are dropped only from a lower portion of the hole 2 and the hole 2 is clogged with the powders 3. In this state, the light that has been projected from the light projecting unit 41 is reflected on the upper surface of the powders 3 on the hole 2, and the reflected light is received by the light receiving unit 42. In this state, the amount of received light received by the light receiving unit 42 is almost the same as that in the state shown in FIG. 1A.

FIG. 1D shows a state where the bottom opening of the hole 2 is made in closed state by the opening/closing member 5 and the powders 3 are filled in the hole 2. The illustrated state shows a normal filled state of the hole 2 that has passed by the scraping plate 7 and until right before the powders 3 starts to be dropped. In this state, an amount of light received by the light receiving unit 42 out of the light that has been projected from the light projecting unit 41 is almost the same as that in the state shown in FIG. 1A.

FIG. 1E shows an anomalous state where some of the powders remain in the hole 2 because only a part of the bottom opening of the hole 2 is made in opened state due to anomalous opening/closing of the opening/closing member 5 of the measuring box 2. In this state, the amount of light received by the light receiving unit 42 changes according to the amount of the part of the bottom opening of the hole 2 opened by the opening/closing member 5. However, the amount of received light is between that in the state shown in FIG. 1B and that in the state shown in FIG. 1D.

Among the positions 1) to 4) as described above, the position 1) is used for monitoring filling failure. Specifically, the optical sensor 4 continuously monitors the upper surface of the powders 3 in the holes 2 and the state of the main surface of the plate member 1, and if the output from the optical sensor 4 does not change while the hole 2 moves an angle as one interval (one operation), the hole 2 is filled normally. In other words, the output from the optical sensor 4 when the optical sensor 4 monitors the state of the main surface of the plate member 1 (FIG. 1A) and that when the optical sensor 4 monitors the upper surface of the powders 3 in the hole 2 (FIG. 1D) are not different.

In contrast, the optical sensor 4 continuously monitors the upper surface of the powders 3 in the holes 2 and the state of the main surface of the plate member 1, and if the output from the optical sensor 4 changes while the hole 2 moves an angle as one interval (one operation), the hole 2 is filled anomalously. In other words, if the upper surface of the powders is not at a position defined by the optical sensor as shown in FIG. 1E, which means that filling failure occurs, the output from the optical sensor 4 when the optical sensor 4 monitors the state of the main surface of the plate member 1 (FIG. 1A) and that when the optical sensor 4 monitors the state of the upper surface of the powders 3 in the hole 2 (FIG. 1E) are different.

The position 3) is highly preferable from a view point of stable operation. FIGS. 1B, 1C and 1D show states where the optical sensor 4 operates for monitoring dropping anomaly as described in 3).

Specifically, the optical sensor 4 continuously monitors the upper surface of the powders 3 in the holes 2 and the state of the main surface of the plate member 1, and if the output from the optical sensor 4 changes while the holes 2 moves an angle as one interval (one operation), the powders 3 are dropped normally. In other words, if the upper surface of the powders is not at a specific position as shown in FIG. 1B, which means that the powders are normally dropped, the output from the optical sensor 4 when the optical sensor 4 monitors the state of the main surface of the plate member 1 (FIG. 1A) and that when the optical sensor 4 monitors the upper surface of the powders 3 in the hole 2 (FIG. 1B) are different.

In contrast, the optical sensor 4 continuously monitors the upper surface of the powders 3 in the holes 2 and the state of the main surface of the plate member 1, and if the output from the optical sensor 4 does not change while the hole 2 moves an angle as one interval (one operation), the powders 3 are dropped anomalously. In other words, if some or whole of the powders are not dropped from the hole 2, and thus the upper surface of the powders remains at the specific position, as shown in FIG. 1C, which means that the powders are anomalously dropped (dropping failure), the output from the optical sensor 4 when the optical sensor 4 monitors the state of the main surface of the plate member 1 (FIG. 1A) and that when the optical sensor 4 monitors the upper surface of the powders 3 in the hole 2 (FIG. 10) are not different.

Especially in FIGS. 1B and 10, the bottom opening of the hole 2 is in opened state, and thus, the amount of reflected light when the optical sensor 4 monitors the state of the main surface of the plate member 1 as shown in FIG. 1A is significantly different from that when the optical sensor 4 monitors the state where the powders are normally dropped as shown in FIG. 1B. Therefore, detection error can be less frequent and the embodiment is preferable.

When an dropping anomaly occurs, in most cases, only lower portion of the powders 3 are dropped while powders in upper portion of the powders 3 to be dropped remains in place as shown in FIG. 10, or any of the powders 3 are not dropped. Therefore, the output from the optical sensor when the optical sensor 4 monitors the state of the main surface of the plate member 1 (FIG. 1A) and that when the optical sensor 4 monitors the upper surface of the powders 3 in the hole 2 (FIG. 10) are not different.

In the position 2), dropping delay of the powders can be detected. The position 4) can be used for monitoring operation failure of the opening/closing member provided at the bottom opening of the hole 2.

Regarding to where the optical sensor 4 is provided, arranging (fixing) position should be considered. One option is that the optical sensor 4 is fixed on the plate member 1 having the holes 2 formed therein to rotate together with the plate member 1, so that a specific monitor 4 always monitors the upper surface of a specific hole 2. In this case, error due to the fixing method, vibration of the optical sensor, or the like is likely to occur.

Therefore, it is preferable to fix the optical sensor 4 on a mechanical member, which is separated from the plate member 1 and does not move. In this case, however, it is impossible for the optical sensor 4 to keep monitoring the upper portion of a specific hole 2 that is always moving. Also, in order to detect the condition of the upper portion of only the hole 2, the signal from the optical sensor has to be selected for a specific time range, and thus a burden is on the control of the device. The signal from the optical sensor has to be selected corresponding to a position relating to the operation timing by acquiring a timing signal from an appropriate rotating shaft provided in the powder filling packaging machine via a cam or retrieving a signal from a part (varicam) for electrically and precisely controlling circumferential angle of a rotating shaft, for example. Generally, one timing signal is retrieved for each operation of dropping the powders 3 to fill a packaging bag (operation of moving an angle for one measuring box when the plate member rotates, and one reciprocating operation when the plate member reciprocates), and thus it is difficult to provide a high-speed device.

Therefore, in order to provide the optical sensor 4 on a mechanical member that is separated from the plate member 1 and that does not move without causing a load on control for the device, the optical sensor 4 may be configured to continuously monitor the upper surface of the powders 3 in the holes 2 and the main surface of the plate member 1. For example, if the plate member 1 having the holes 2 provided therein rotates, the optical sensor 4 is positioned above the moving path along which the top openings of the holes 2 move as the plate member 1 moves. Then, the optical sensor 4 continuously monitors the holes 2 and the plate member 1 alternately.

By monitoring in such way, there is no need to retrieve the signal from the optical sensor only for a specific time range specified corresponding to the operation timing. Therefore, simple and reliable control can be available.

Especially when the dropping is monitored at the position 3), normal opening/closing operation of the opening/closing member and normal dropping of the powders can be detected in normal operation. In normal operation, that is, when the powders 3 normally drop, the light receiving unit 42 detects very little amount of reflected light in stable condition. In anomalous operation, that is, dropping anomaly, the cause of the anomalous operation such as anomalous operation of the opening/closing member, foreign substance, or insufficient flow of the powders is checked and identified.

When filling is monitored at the position of 1), normal closing operation of the opening/closing member is detected in normal operation. In anomalous operation, that is, when the powders are insufficiently filled, the cause of the anomalous operation such as leaking due to anomalous closing operation (partly open) of the opening/closing member, insufficient supply of powders due to foreign substance mixed in, or the like is detected.

Since this embodiment is described using the plate member 1, the member 1 and the plate portion are integrated. However, the member 1 may have a circular plate portion and a portion near the center of the member 1 surrounded by the plate portion may not be in plate shape.

Second Embodiment

FIG. 3 is a view showing a powder supply device and a powder filling packaging machine of a second embodiment of the invention. In the description of this embodiment, the same reference numerals are designated to the components same as those already described and their description will not be repeated. The powder supply device and the powder filling packaging machine according to this embodiment is for describing powder filling and powder dropping in the powder filling packaging machine using a plate member reciprocating. In this embodiment, a member 1 as a whole is in a plate shape, and thus the member 1 is called a plate member 1. Here, FIG. 3 is a schematic sectional view and an optical sensor 4 is provided right above a position where the powders are dropped.

In FIG. 3A, a bottom opening of a hole 2 is made in closed state. The plate member 1 provided with the holes 2 that function as measuring boxes reciprocate due to the reciprocating mechanism 18. First, powders are filled onto the main surface of the plate member 1 from the hopper 13 when the hole 2 is on left side of the scraping plate 7. Then, the hole 2 moves rightward as a forward movement due to the reciprocating movement of the plate member 1, whereby powders 3 are filled in the hole 2 and measured by a scraping plate 7. At this time, there is nothing right below the monitoring point of the optical sensor 4, and only a chute 15 for dropping the powders 3 to insert them into the packaging bag and the like present further below.

In FIG. 3B, the plate member 1 further moves rightward, and the hole 2 reaches an end of the opening/closing member 5 that is a sliding bottom plate provided below the plate member 1 so as to start dropping the powders. At this time, the hole 2 is not right below the optical sensor 4 and the optical sensor 4 is above the main surface of the plate member 1. Therefore, FIG. 3B shows a monitoring situation similar to FIG. 1A.

In FIG. 3C, the plate member 1 is at a position corresponding to the end point of the forward path and the start point of the backward path. At this time, the opening/closing member 5 makes the bottom opening of the hole 2 in opened state. Then, the powders 3 are dropped from the hole 2 so as to empty the hole 2. Therefore, FIG. 3C shows a monitoring situation similar to FIG. 1B.

FIG. 3D shows a case where a dropping failure of the powders occurs when the plate member 1 is in a state shown in FIG. 3C, which is a monitoring situation similar to FIG. 1D. In this case, dropping anomaly is detected.

By providing the chute 15 that is a powder guide unit and a sealing unit 16 to the powder supply device according to the embodiment, the powder supply device can function as a powder filling packaging machine.

When a plate member 1 that has holes 2 functioning as measuring boxes arranged in a straight line is used as the powder supply device and the powder filling packaging machine of this embodiment, the powders are supplied onto the plate and filled in a hole at an end of one reciprocating movement (start point of the forward path or end point of the backward path) and the powders are dropped from the hole at the other end of one reciprocating movement (end point of the forward path or start point of the backward path). Since all holes 2 operate similarly in a reciprocating machine, the machine functions as a multiple-line filling packaging machine.

Preferable embodiments of the invention have been described as the first embodiment and the second embodiment. The invention is not limited thereto and various alternatives can be made.

For example, when the powders are filled in the holes 2 as measuring boxes, the hopper 13 and the scraping plate 7 can be integrated to be a powder supply unit 14. In this case, the holes 2 functioning as measuring boxes may be scraped by the powder supply unit 14. Alternatively, the holes may pass through the scraping plate 7 right after the powders are filled or other options are available. In this case, a predetermined section occupied by the powder filling unit 14 can be shortened, so that a position where the sensor 4 is arranged can be selected more flexibly.

The upper surfaces of the powders 3 in the holes 2 may have the same height as that of the main surface of the plate member 1. In this case, very few powders 3 are deposited on the main surface of the plate member 1, so that wasting powders can be reduced. Also, upper portion of the powders 3 in the holes 2 are scraped to have a specific filling height. Accordingly, a specific amount, that is, a specific volume of powders are measured in a measuring box.

The holes 2 may be formed by directly forming penetrating holes of desired volume in the plate member 1, or by providing, on the plate member 1, members to be hollow cylinder measuring boxes of a plurality of types having different hollow diameters in a removable condition. In the latter case, size of the measuring box can be changed depending on packaging amount into a packaging bag 8.

The opening/closing member 5 may be implemented by arranging a shutter, which can freely open/close, at the bottom opening of the hole 2. Alternatively, the opening/closing state of the opening/closing member 5 can be determined by presence/absence of a plate subjected to surface treatment with Teflon (registered trademark) or other bottom plates that slide with the bottom opening of the hole 2.

The invention is described using the optical sensor 4 for monitoring the upper surfaces of the powders 3 that have been filled in the holes 2 and measured. However, any type of sensor such as an optical sensor, a capacitance sensor, or an ultrasonic sensor can be used as long as the sensor can determine whether or not the upper surface of the powders 3 is at a predetermined position at any distance from the sensor. An optical sensor is desirable because it is advantageously less affected by temperature change, less affected by difference of powder types, and highly precise. Further, since the upper surface of the filled powders 3 after the measurement is made flat by passing by the scraping plate or the like, light reflection can be easily applied. From such advantages, an optical sensor using a light-emitting diode or laser in a light projecting unit is preferable. Particularly, an optical sensor that has a light projecting unit and a light receiving unit to sense an amount of reflected light from the upper surface of the powders in a V-formation is more desirable.

EXAMPLES

The invention will be now described herein with reference to specific examples; however, the invention is not limited to the examples.

Example 1

A powder filling packaging machine having a basic configuration according to the first embodiment as shown in FIG. 2 is used. However, a moving mechanism 18 is arranged at a different position. In this example, a plate member having holes 2 penetrating through the plate member and arranged on respective circumferences of two concentric circles including inner and outer circles on the main surface is used as a member 1. Twenty-four penetrating holes 2 are formed on each of the inner and outer circles. Each of the penetrating holes formed on the inner circle has a diameter of 3 mm and each of the penetrating holes formed on the outer circle has a diameter of 8 mm. The member used in the example is in a disk shape having a thickness of 5 mm. Further, powder filling units 14 that can measure two types of powders are provided for the inner circle and the outer circle, whereby the powder filling packaging machine for deoxidant is formed.

A shutter opening/closing cam is set in such a manner that a shutter, which is an opening/closing member 5 of the bottom opening of each of the penetrating holes 2, opens for an angle as three intervals for the penetrating holes 2, that is, 45° after the hole passes by the scraping plate 7 for measurement.

Here, with a fixing jig extending from a mechanical part that does not move, optical sensors 4 are arranged right above positions of the penetrating holes that have moved an angle of two holes after shutters open on both of inner and outer circles. As the optical sensor 4, a V-form reflecting optical sensor having a light projecting unit and a light receiving unit adjacent to each other is used. The optical sensor 4 is arranged in such a manner that the amount of reflection from the height position of the powders after passing by the scraping plate 7 is made maximum. Then, the optical sensor 4 is configured to output a normal signal when no powders 3 exists.

At the same time, a cam is arranged on an inner mechanical shaft of the powder filling packaging machine and configured to output one pulse each time when moved an angle as one interval for holes, corresponding to 15° in a circumferential angle of the plate member 1 (one operation) so as to generate a signal for number checking, which is retrieved.

A sequence is configured to determine that the powders are dropped normally if the signal for number checking and the normal signal from the optical sensor 4 are alternately input to a sequencer and that a dropping failure occurs if the normal signal from the optical sensor 4 is not input between two sequential signals for number checking, also upon the dropping failure, to make an alarm sound and light an alarm lamp as well as to make emergency stop of the packaging machine.

In the filling packaging machine, volume measurement for deoxidant powders of iron powder type of 0.2 g (maximum particle diameter: 200 μm, apparent relative density: 3.1) is performed by the penetrating holes 2 functioning as measuring boxes on the inner circle and for moisturizing agent powders of 0.2 g (maximum particle diameter: 2 mm, apparent relative density: 0.8) is performed by the penetrating holes 2 functioning as measuring boxes on the outer circle. And filling and packaging is performed at a speed of making 720 small packages of deoxidant in every minute.

At this time, if powders are normally dropped from the penetrating holes 2 on the inner and outer circles respectively, the sensor alternately detects the state shown in FIG. 1A (where the upper surface of the powders on the plate member between the measuring boxes is at a position defined by the sensor) and the state shown in FIG. 1B (where the powders are dropped from a measuring box and the powders do not exist at the position defined by the sensor). The sensor intermittently generates the normal signal once in about 0.08 second. The signal and the signal for number checking from the filling packaging machine are alternately input to the sequencer (once in about 0.08 second), and thus the powder packages can be manufactured without any false operation.

Then, a wad is purposely put in a lower portion of one of the measuring boxes to cause a dropping failure. Accordingly, the signal for number checking is sequentially input at a part of the measuring box, then the filling packaging machine is stopped with an alarm sound and an alarm lamp.

Example 2

In this example, a powder filling packaging machine having a basic configuration according to the second embodiment as shown in FIG. 3 is used. In this example, a plate member 1 having a thickness of 10 mm and provided with ten measuring boxes 2 in a columnar shape having a diameter of about 6 mm and a depth of 10 mm arranged on a straight line. The powder filling packaging machine is configured to be a multiple-line (10 lines) powder filling packaging machine for deoxidant. The plate member 1 for measuring powders 3 in the powder filling packaging machine reciprocates perpendicularly to the arrangement of the penetrating holes 2 to function as measuring boxes and the operation thereof is set by a varicam arranged on a main rotating shaft of the powder filling packaging machine.

A laser photoelectric sensor as an optical sensor 4 is arranged via a fixing jig from a frame of the powder filling packaging machine at a position where a sliding bottom plate at a bottom opening of a penetrating hole 2 does not exist and deoxidant powders (maximum particle diameter: 250 μgym) are dropped from the penetrating hole 2.

The penetrating hole 2 moves from a 0 (zero) degree position of rotating angle of the main rotating shaft as a start position, moves horizontally along the forward path so as to pass by the hopper 13 and the scraping plate 7, reaches the other end at 180 degree so as to drop all powders in the penetrating hole 2, and then moves horizontally again along the backward path back to 360 degree (0 degree).

During the operation, the optical sensor monitors the states where the powders 3 do not exist (FIG. 3A)->powders 3 exist (FIG. 3B)->powders 3 do not exist (FIG. 3C)->powders 3 exist (FIG. 3B)->powders 3 do not exist (FIG. 3A) in normal operation. Therefore, a sequence is configured to determine that the powders are dropped normally if a signal indicating “powders exist” is input twice between the rotating angle of 160 degree and 210 degree, and to determine that the powders are dropped anomalously if a signal indicating “powders exist” is input only once (instead of the state of FIG. 3C, the sensor monitors the state of FIG. 3D). The powders 3 of 1.2 g (apparent relative density: 2.5) are measured to fill and package deoxidant while an alarm is to be issued and the machine is to be stopped upon anomaly. The powder packages can be manufactured without any false operation.

Then, a wad is purposely put in a lower portion of one of the measuring boxes 2 to cause a dropping failure. Accordingly, the filling packaging machine is stopped with an alarm.

Example 3

A device similar to the example 1 is used. Further, a sensor of similar type to that used in the example 1 is additionally provided at a position of a measuring box 2 right before a shutter at the bottom opening of the measuring box 2 is made in opened state. The additionally provided sensor 4 is configured in such a manner that a signal indicating normal can be retrieved from the sensor 4 when the powders 3 exist on the main surface of the plate member 1. And the sequence is configured in such a manner that an alarm or the like is output as the filling failure when the normal signal to be sequentially input is intermitted.

In this state, it is confirmed that small packages of deoxidant can be sequentially filled and packaged in a condition similar to the example 1. Then the device is operated with a shutter at the bottom opening of only one of the measuring boxes 2 opening about one third assuming a shutter closing operation failure.

As a result, the filling failure is monitored and the packaging machine is stopped with an alarm sound and an alarm lamp. In the hole 2, the powders 3 are once filled and then dropped through the gap made by the shutter and thus the hole 2 is in as state in which only few powders 3 are left in the hole 2 as shown in FIG. 1E.

Further, when the operation is continued in a similar filling failure state without operating the additionally provided sensor 4 (with no anomalous input), a sensor 4 provided at a position of the hole 2 that has moved an angle of two holes after the shutter thereof is made in opened state monitors the state as a dropping failure so as to stop the packaging machine with alarm sound and alarm lamp.

INDUSTRIAL APPLICABILITY

According to the powder supply device of the invention, dropping of the powders 3 filled in the holes 2 can be precisely monitored and thus the powders can be stably supplied. Further, according to the powder filling packaging machine and the method of manufacturing powder packages, the powders can be stably filled into the packaging bags. 

1. A powder supply device comprising: a member including a plate portion having holes formed to penetrate through the plate portion; a moving mechanism that moves the member in such a manner that top openings of the holes move along a specific moving path; an opening/closing member that makes bottom openings of the holes in closed, state and opened state as the member moves; a powder filling unit that fills a specific amount of powders in each of the holes within a predetermined section in the moving path; and a sensor that is provided above a path within a section other than the predetermined section in the moving path and that continuously monitors the moving path on the plate portion.
 2. The powder supply device according to claim 1, wherein the sensor is provided above the moving path at a position where the bottom openings of the holes are in opened state.
 3. The powder supply device according to claim 1, wherein the sensor includes: a light projecting unit that projects a light; and a light receiving unit that receives reflected light of the projected light, so as to detect an amount of the received light.
 4. The powder supply device according to claim 1, wherein the plate portion is in a disk shape, and the moving mechanism is a rotating mechanism that moves the member in such a manner that the plate portion rotates.
 5. The powder supply device according to claim 1, wherein the moving mechanism is a reciprocating mechanism that reciprocates the member.
 6. A powder filling packaging machine comprising: a member including a plate portion having holes formed to penetrate through the plate portion; a moving mechanism that moves the member in such a manner that top openings of the holes move along a specific moving path; an opening/closing member that makes bottom openings of the holes in closed state and opened state as the member moves; a powder filling unit that fills a specific amount of powders in each of the holes within a predetermined section in the moving path; a guide unit that guides the powders dropped from the holes when the bottom openings of the holes are in opened state into a packaging bag; a sealing unit that seals the packaging bag in which powders guided by the guide unit are filled; and a sensor that is provided above the moving path within a section other than the predetermined section in the moving path and that continuously monitors the moving path on the plate portion.
 7. The powder filling packaging machine according to claim 6, wherein the sensor is provided above the moving path at a position where the bottom openings of the holes are in opened state.
 8. The powder filling packaging machine according to claim 6, wherein the sensor includes: a light projecting unit that projects a light; and a light receiving unit that receives reflected light of the projected light, so as to detect an amount of the received light.
 9. A method of manufacturing a powder package comprising: moving a member including a plate portion having holes formed to penetrate through the plate portion in such a manner that top openings of the holes move along a specific moving path; making bottom openings of the holes in closed state by an opening/closing member; filling a specific amount of powders in each of the holes within a predetermined section in the moving path; making the bottom openings of the holes in opened state and dropping the powders in the holes; guiding the powders into a packaging bag positioned below the plate portion to fill the packaging bag; and sealing the packaging bag, wherein a sensor that is provided above a path within a section other than the predetermined section in the moving path continuously monitors the moving path on the plate portion and if anomaly is detected, a predetermined operation is performed.
 10. The method of manufacturing a powder package according to claim 9, wherein the monitoring is performed when the bottom openings of the holes are in opened state to monitor the powders dropping from the holes.
 11. The method of manufacturing a powder package according to claim 9, wherein the monitoring is performed by using an optical sensor that includes: a light projecting unit that projects a light; and a light receiving unit that receives reflected light of the projected light, so as to detect an amount of the received light. 